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This is my original rear bulkhead with the hat shelf. Let's just say that its seen better days. It was being held together with 100 mph duct tape and good intentions. After the last hole appeared, I decided to build a new one rather than getting one from Plane Plastics. The reason for this was, I wanted to customize the hat shelf area so that I could store all the essentials that I normally keep in a container in the luggage area. |
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Construction method is standard blue foam-fiberglass. This is the only shot I have of the original foam pieces. Fiberglass both sides, epoxy the pieces together, and then fiberglass the whole thing. |
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Front view of completed bulkhead ready for finishing. After searching long and hard on the Internet, I found out how those composite homebuilders got their interiors looking so good. Its a simple three step process: Step 1: After minimal surface prep, Prime surface with Gray Primer. Step 2: After primer is dry, evenly apply Plasti-Kote Fleck Stone Base Coat availabe at Wal-Mart. Step 3: Once base coat is dry, apply Clear Topcoat. |
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This is the rear of bulkhead. Notch is for the RG gear pump. If I had an FG this notch would not be necessary and I'd be able to use the entire width for storage. My hat shelf is slightly deeper than the original, hence the notch.
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Completed Bulkhead after final coat of Clear Topcoat. It hides a host of surface imperfections.
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New Bulkhead installed. Room for five quarts of oil, fuel sampler, paper towels, cans of cleaner, etc. There is also a door that covers the hat shelf area hinged from the top so that the bulkhead looks flush when closed. I haven't completed finishing and install of the door yet.
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New Bulkhead installed.
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© William W. Curtis 2002-2008
All rights reserved.
Last Updated: 11 March 2008